Electrical connection means



Oct. 31, 1944. F. BEAL ELECTRICAL CONNECTION MEANS Original Filed July 31, 1959 26 l2 -Fay-Beal INVENTOR.

Patented Oct. 31, 1944 Fay Beal,

Bronson, Mich., assignor to H. A.

Douglas Mfg. Co., Bronson, Mich., a corporation of Michigan Continuation of application Serial No. 287,503,

July 31, 1939. This ap Serial No. 455,855

6 Claims.

This invention relates generally to electrical connection means and particularly to connectors adapted for detachable association with respect to a lamp Or other electrical apparatus for establishing a through connection between the source, line, and lamp.

More specifically, the invention is directed to a connector provided with a plurality of terminal posts, or receptacles, each of which is adapted to detachably resiliently receive and hold one of a plurality of terminal studs which project from the rear extremity of a headlamp.

This application is a continuation of my earlier formally abandoned application Serial No. 287,- 503 filed July 31, 1939.

One particular object is to provide a connector having at least a single terminal post or receptacle that is associated with a mounting member of insulating material in such a manner that the receptacle will float or adjust itself to accommodate a terminal stud when the latter is inserted into the receptacle.

Another object is to provide a construction of the character just referred to, in which each receptacle is formed with substantially aligned aperti'res through which insulated conductor wires are threaded so as to maintain the wires in a converging relation, particularly adjacent the rear extremity of the conductor, whereby portions of the wires may be enclosed by a suitable casing, preferably of resilient insulating material.

Another object is to provide improved means whereby the bared ends of the conductor wires may be simultaneously permanently secured to the terminal receptacles or posts.

A further object is to provide a connector that may be economically manufactured and assembled on a production basis.

Other objects and advantages of this invention will be apparent after considering the description hereinafter set forth in conjunction with the drawing annexed hereto. 1

Referring to the drawing:

Figure 1 is a relatively small side view of a connector, embodying the invention, as applied to an electrical headlamp of a vehicle;

plication August 24, 1942,

Figure 2 is a larger side view of the connector,

partially in section, disconnected from the lamp, and with its casing removed;

Figure 3 is a front end view of the unit shown in Figure 2, with the conductor wires and easing removed;

Figure 4 is a rear end view in elevation of the unit shown in Figure 3;

Figur 5 discloses certain details of one of the terminal posts or receptacles;

Figure 6 is a surface development of one of the terminal posts; and

Figure 7 is a section taken substantially on the line of Figure 6.

Referring particularly to Figure 1 of the drawing, wherein the preferred form of the invention is disclosed, numeral I generally designates a vehicle headlamp which is adapted to be sup ported with a suitable housing or to-a mounting not shown, and 2 generally designates a connector which is adapted to be detachably connected to the headlamp. Obviously, the connector may be designed and constructed for use in connection with electrical apparatus other than a vehicle headlamp, and it is to be understood that the connector may be provided with one or a plurality of terminal posts or receptacles depending on the use or application of the connector.

The headlamp may be provided with any desirable number of terminal connections or studs, but as herein shown, is preferably provided with a terminal stud 3, and a pair of studs 4, the latter of which are arranged in spaced apart relation substantially equidistant from the focal axis of the headlamp, while stud 3 is located above said axis intermediate said studs Only one of the studs 4 is shown in Figure 1. The studs 3 and 4 may be constructed as desired, but as herein shown, are preferably comprised of sheet metal and formed with angular projections which extend rearwardly of the headlamp, each projection being preferably provided with a circular aperture 5, as clearly shown in Figures 2 and 5, the purpose of which will be described later. The free extremities of the studs are preferably made planar or flat, the extremity of the stud 3 being arranged horizontally, and the extremities of studs 4 vertically or at right angles to the plane of stud 3.

The connector 2 may include a casing 6 preferably of resilient insulating material, whereby the same may be stretched to receive the unit shown in Figure 2. The casing 6 may be of any suitable shape and size, but is preferably provided with a tapered tubular portion which is adapted to maintain the wires leading to the unit in generally close priximity to each other. As shown in the partial section of Figure 1, the casing may be provided with an internal generally annular recess which is adapted to receive the marginal edges of the mounting 'l.

The mounting l is preferably constructed from a relatively thin flat plate of insulating material,

and made annular in shape, except for a beveled portion adjacent its lower extremity. Obviously, the mounting may take a form distinguishable from a plate. The mounting I is preferably provided with three terminal posts or receptacles, generally designated 8, 9, and Ill, which are arranged to cooperate with the headlamp terminal studs 3 and 4, respectively. The receptacles may be arranged on and connected to the mounting plat in any desirable manner, but as hereinafter described, are preferably permanently secured to the plate in a manner whereby each of the receptacles may laterally adjust itself with respect to the stud it is adapted to receive. In view of the fact that the mounting I and easing 8 are both constructed of insulating material, it will be evident that when all of the parts are assembled the mounting and casting provide a housing for the receptacles and portions of the conductor means whereby to protect and insulate the recep-' tacles and conductor means. It will also be evident that the housing formed by the mounting l and casing 6 provides an arrangement whereby opposite sides or portions of the mounting forming a part or the housing provide abutment means which are engaged by portions of the receptacles. More specifically, portions of the mounting 1 forming a part of the housing form abutment means which are surrounded by pertions of the casing 6 which constitutes part of the housing 'so that in fact those portions of the receptacles which assist in holding the receptacles in the apertures are disposed in recesses as more or less illustrated in Figures 1 and 2 of the drawing.

Inasmuch as all of the receptacles are identical, a description of one is believed suflicient. Referring particularly to Figures 2 and 5, and describing particularly the receptacle generally designated 8, the same is connected to the plate in such a manner that the major part is located adjacent one side preferably the rear side. The

receptacle 8 is preferably formed according to Figures 2 and 5, from a resilient sheet metal stamping, as disclosed --in Figure 6. The receptacle is constructed to include a pair of spaced apart substantially flat parallel contacting portions II and I2, which are adapted to grip the stud 3. These portions II and I2, which may be called legs, are formed by bending the stamping back upon itself, and are preferably joined or connected together by an enlarged substantially cylindrical portion I3, the axis of which is arranged substantially transverse to the general longitudinal extent or axis of the receptacle. The portion i3 may be arranged in an offset relation with respect to the portions II and 2. The portion l3 provides means for generally increasing the resiliency of the receptacle or specifically, the expansibility and contractibility of the leg portions, but, if desired, such resiliency may be accomplished by means other than said enlarged portion.

The leg portion H is preferably provided with a flat base portion 4 adapted to engage the left side or front end of the plate 1 in certain instances. The portion I4 is preferably arranged at right angles to portion H, and provided with an angular tapered portion I5 arranged substantially at right angles to portion I 4 and parallel to portion Portion II is also preferably provided with a depression l6 extending inwardly into the receptacle to provide a detent adapted to cooperate with the aperture 5 in the stud 3, in

tween the receptacle and stud. The portion H is preferably provided with a relatively large annular aperture l1, and the angular tapered portion IS with a notch la, the purposes of whichfwill be described hereinafter. u

The leg portion l2 which lies opposite the portion ii is preferably provided with a ccntinua-' tion portion M, which is preferably onset and arranged parallel with respect to portion I2. An abutment 20in the form of a projection struck outwardly of the receptable is preferably provided adjacent the junction 60 joining portions I2 and It, for normally engaging the right hand side or g rear end of plate I. In other words, base H of portion II, and abutment 20 are arranged to engage the opposite sides or ends ofthe mounting. As clearly shown in Figures 2 and 5, the continuation l9 and that portion of portion II which lies opposite continuation ID, are preferably arranged within a rectangular aperture 2| The corresponding portions of receptacles 8 and it] are of course arranged within the corresponding rectangular apertures 22 and 23, respectively.

The mounting 1, above referred to, is also preferably provided with a plurality of spaced apart circumferentially arranged circular apertures 24,

- and as most clearly shown in Figure 5, the receporder to more fully insure a latched relation betacle 8 is preferably permanently secured to the plateby means of a tubular rivet 25, the tubular portion of which extends loosely through the aperture 24, and aperture ll of portion l4. The circular apertures 24 in addition to said circumferential arrangement are located on radial lines passing through the center of the mounting and centers of the apertures 2| through 23.

To assemble the receptacle 8 with the mounting I, it is only necessary to thread the portions I5 and I4 through the rectangular aperture 2| substantially to the position shown, at least to a position whereby the continuation l9 may also be inserted or pressed into the rectangular aperture 2| Thereafter the rivet 25 is inserted through apertures 24 and i1 and headed over as shown. Since the portion I5 is tapered, it can be easily guided and inserted into the aperture 2|.

It is to be noted that one particular object of the invention is to secure each receptacle to the mounting in such a manner that each receptacle may float or laterally adjust itself so as to better accommodate the stud it is adapted to receive from the headlamp. This is preferably accomplished by making the diameters of apertures 24 and i1 slightly greater than the outside diameter of the rivet 25, in order to permit relative movement between the leg portions H and i2. Moreover, such relative movement is accomplished by making the tubular rivet 25 of a length somewhat greater than the combined thickness of plate 1 and portion l4, so as to allow the portion 4 to slightly tilt or otherwise move relative to the face of plate 1 when the stud 3 is being received between the leg portions. Inasmuch as the continuation l9 and that portion of the leg lying opposite continuation l9 are substantially confined within the aperture 2| against excessive movement, the relative movement or flexion of the leg portions takes place at a region primarily remote from the entrance end of the receptacle. These various parts or portions just referred to, may be constructed and arranged to act separately or in combination, whichever is desired.

The general width of the receptacle, or specifically the width of leg portion H and continuatlon l9 are preferably slightly less than the length of the rectangular aperture 2| in the mounting, so as to permit the portions l4 and I! of the receptacle 8 to be easily threaded through said aperture. Moreover, the difference in dimensions is preferably such that the aperture more or less assists to maintain the receptacle in an erect position .or perpendicular to the mounting. Obviously, these minor details may be changed or altered so as to accomplish the results desired.

The continuation l9 and that portion of portion II which lies opposite the continuation 19 are preferably spaced apart to provide an enlarged entrance opening for the terminal stud, and in view of ,thjs opening, the stud is guided for passage in between the resilient leg portions H and [2. The junction 60 connecting portion I2 I and continuation I9 is preferably formed to provide a cam surface, assisting to guide the stud 3 directly in between the portions H and I2.

In order to provide more efilcient electrical engagement between the portions II and I2 and the terminal stud 3, the marginal longitudinal edges of portion l2 are preferably turned inwardly as indicated at 26 in Figure 6, so as to provide arrises 21, which are adapted to bite into or otherwise definitely engage one planar side of the terminal stud 3. One extremity of each of the inturned portions 26 is preferably provided with a cam surface 6| which assist in directing the stud into the receptacle, like the cam surface of junction 60. e

In order to limit or predetermine the inwardmovement of the stud 3 into the receptacle, either the portion l2 or the substantially cylindrical portion l3 may be provided with an integral inwardly struck tongue 28, which functions as a stop or abutment which the entering end of the stud 3 is adapted to engage. The tongue 28 may be located where most desired, but as herein shown, it is preferably provided adjacent the junction between the portion 12 and the -substantially transverse cylindrical portion l3, at a point whereby the aperture in the stud 3 will be arranged in a position to receive or otherwise cooperate with the detent ll; of portion II. It has been found desirable to provide the receptacle with improvements such as It, 26 and 28; however, it is to be distinctly understood that such improvements are not absolutely necessary in every instance to produce an operative device.

The manner in which the various insulated conductors are secured to the receptacles of the connector will now be considered. Referring particularly to Figures 2 and 5, it will be apparent that the substantially cylindrical portion I3 of .receptacle 8, is provided with a pair of aligned circular apertures 29 and 30 arranged transversally to the axis of said portion. The axes of these apertures are preferably inclined with respect to the longitudinal axis of the receptacle so that a conductor after being threaded through the apertures 23 and 30 may be positioned to be more easily threaded into and through the tubular rivet 25, the bared end 3| of conductor 32 being adapted to be manually bent over into the notch l8 and firmly secured in place by solder 33, The conductors 34 and 35 are likewise secured to the receptacles 9 and i0, respectively. By this arrangement, the conductor wires are brought together in converging relation at a point not far distant from the mounting plate 1, in order that a suitable casing or hood, such as 6, may be detachably arranged about the unit, as clearly shown in Figure 1.

The particular construction shown has been found very advantageous for the reason that in mass production all of the bared ends of the conductors may be simultaneously secured within the notches l8 of the portions Hi. This may be accomplished by bending the bared end portions of the conductors into the notches and then d'pping the unit into a container filled with liquid solder, the height of the solder within the container preferably being such that the solder will adhere only to the bared portions 3| and the tapered portions l5, as clearly shown in Figure 2.

To apply the connector to a headlamp, as shown in Figure 1, it is only necessary to arrange the connector so that the terminal stud 3 and the pair of terminal studs 4 register with the entrance openings in the receptacles 8, 9 and 10, respectively, and by placing pressure upon'the connector in a direction toward the lamp, the terminal studs will snap into place, as clearly shown in Figure 2, to establish an efficient electrical and mechanical connection. The stops or abutments 20 on the receptacles function to maintain the receptacles in a substantially perpendicular position with respect to the mounting plate I, when pressure is applied upon the connector during its assembly with the headlamp. In its commercial application, the terminal studs 3 through 4 are preferably ductile in character, and in mass production ofttimes become distorted or bent out of shape to such an extent that it is almost impossible to assemble a connector with the studs. In view of the improved construction described above, the receptacles on the connector are laterally adjustable or in a positon to float and accommodate themselves with respect to the terminal studs which might be subjected to the conditions just mentioned.

Having thus described my invention, it is obvious that various modificat ons may be made in the same without departing from the spirit of the invention; and, therefore, I do not wish to be understood as limiting myself to the exact form, construction, arrangement, and combination of parts herein shown and described.

I claim:

1. In a device of the class described, the combination of an insulating body having an aperture therein, and a contact received in said aperture, said contact having wire holding and terminal receiving portions arranged side by side in offset relation, said wire holding portion being arranged to receive the extremity of a wire projecting into the body so that said wire extremity is disposed with respect to a portion of the body in a manner whereby the wire extremity is concealed from view from at least one position, and said terminal portionbeing generally U-shaped and constituted by spreadable connected bladelike legs adapted to receive between them and yieldably grip a blade-like terminal adapted to be projected into said aperture, the connection between the legs being enlarged to improv the gripping action of the legs, at least one of said legs constituting an abutment means to interlock with the aperture and limit movement of the contact relative to the aperture in one direction, and additional means on the contact for interlocking with the body for limiting movement of the contact relative to the body in an opposite direction, said contact being yieldable so as to permit the same to yield during insertion of the contact into the body.

2. Electrical connection means including insulation means having abutment means adjacent a first side and planar abutment means adjacent a second'side, an opening extending through said insulation means, said insulation means also being provided with portions of insulation extending in opposite directions and axially outwardly side for limiting the axial movement of said receptacle in one direction in said opening, an 011'- set provided on one of said legs adjacent one extremity of the receptacle so that a portion of the offset more or less engages said planar abutment means adjacent the second side of said insulation means so as to assist in holding the receptacle I against movement in an opposite axial direction, said offset being insertable into said opening in advance of the opposite extremity of said receptacle when the receptacle is being inserted, and said receptacle being provided with means adjacent said offset which may be engaged by a conductor.

3. Electrical connection means including insulation means having a first side provided with side for limiting the axial movement or said receptacle when same is disposed in said opening, an onset provided on one of said legs adjacent one extremity of-the receptacle having a portion more or less engaging the abutment means adjacent the second side of said insulation means, said offset being insertable into said opening in advance of the opposite extremity of said receptacle when the receptacle is being inserted-and assisting to hold the'receptacle to the said insulation means, and means provided on said receptacle adjacent said ofiset for securing a conductor to said receptacle.

5. In a device of the class described, the combination of an insulating body having an aperture therein, and a contact received in said aperture, said contact having wire holding and terminal receiving portions arranged side by side in ofiset relation, said wire holding portion being arranged to receive the extremity of a wire projecting into the body so that said wire extremity is disposed with respect to a portion of the body in a manner whereby the wire extremity is concealed from view from at least one position, and

abutment means adjacent thereto and a second side provided with abutment means adjacent thereto, an aperture provided in said insulation means, a two legged terminal receptacle insertable into said aperture from said first side, the legs of said receptacle being joined together by an enlarged connecting portion substantially closing off one end of the receptacle, a stop portion on one of said legs engaging the abutment means adjacent said first side for limiting the axial movement of said receptacle in one direction in said aperture, an offset provided on one of said legs having a portion more or less engaging the abutment means adjacent the second side of the insulation means assisting to hold the receptacle against axial movement in an opposite direction, said offset being insertable into said aperture in advance of the receptacle when the latter is being inserted, means adjacent said offset adapted to be engaged by a conductor, and insulation extending substantially perpendicular to both of the sides of said insulation means whereby to substantially surround said stop portion and said offset.

4. Electrical connection means including insulation means having abutment means adjacent afirst side and abutment means adjacent a second side, an opening extending through said insulation means, said insulation means being provided with portions of insulation surrounding said abutment means, a two-legged terminal receptacle insertable into said opening from said first side, said legs being joined by an enlarged connecting portion closing off one end of the receptacle, a stop adjacent one of said legs engaging said abutment means adjacent said first said terminal portion being generally U-shaped and constituted by spreadable connected bladelike legs adapted to receive between them and yieldably grip a blade-like terminal adapted to be projected into said aperture, the connection between the legs being constructed and arranged whereby to improve the gripping action of the legs, at least one of said legs constituting an abutment means to interlock with the aperture and limit movement of the contact relative to the aperture in one direction, and additional means on the contact for interlocking with the body for limiting movement of the contact relative to the body in an opposite direction, said contact being yieldable so as to permit the same to yield during insertion of the contact into the body.

6. Electrical connection means including insulation means having abutment means adjacent a first side and abutment means adjacent a second side, an opening extending through said insulation means, said insulation means being provided with portions of insulation surrounding said abutment means, a two-legged terminal receptacle insertable into said opening from said first side, said legs being joined by a connecting portion closing off one end of the receptacle, a stop adjacent one of said legs engaging said abutment means adjacent said first side for limiting the axial movement of said receptacle when same is disposed in said opening, an offset provided on one of said legs adjacent one extremity of the receptacle having a portion more or less engaging the abutment means adjacent the second side of said insulation means, said ofiset being insertable into said opening in advance of the opposite extremity of said receptacle when the receptacle is being inserted and assisting to hold the receptacle to the said insulation means, and means provided on said receptacle adjacent said ofiset for securing a conductor to said receptacle.

- FAY BEAL. 

